Interface and fabrication method for lighting and other electrical devices

ABSTRACT

Interfaces for electrical (e.g., lighting) devices involve use of electrically conductive edge contacts arranged on or protruding from edges of printed circuit boards (PCBs) that provide or facilitate electrical connections to first and second externally accessible electrical contacts, such as may include threaded and foot contacts of a lighting device including a screw-shaped male base. First and/or second edge contacts of a PCB may protrude through first and second openings in a housing to form first and second externally accessible contact, or directly engage first and second externally accessible contact elements associated with (e.g., retained by) the housing. A contact element retained by a housing may define a slot in the interior of the housing to directly engage an edge contact of the PCB. Electric power is supplied to the PCB via edge contacts without need for intervening wires or soldered connections.

CROSS-REFERENCE TO RELATED APPLICATION(S)

This application is a continuation of U.S. patent application Ser. No.12/730,802 filed on Mar. 24, 2010 and subsequently issuing as U.S. Pat.No. 9,039,271 on May 26, 2015, with the foregoing application and patentbeing hereby incorporated by reference herein, for all purposes.

TECHNICAL FIELD

The present disclosure relates to electrical interfaces and fabricationmethods for lighting devices (including solid state lighting devices)and other electrical devices.

BACKGROUND

Solid state light sources may be utilized to provide colored or whiteLED light (e.g., perceived as being white or near-white), as has beeninvestigated as potential replacements for white incandescent lamps.Solid state light sources are particularly desirable for theirpotentially high efficiency and long life relative to other (e.g.,incandescent, halogen, fluorescent, etc.) light sources. A solid statelighting device may include, for example, at least one organic orinorganic light emitting diode (“LED”) or a laser, optionally coatedwith at least one phosphor to achieve a desired color or combination ofcolors. Combined emissions from multiple solid state and/or phosphoremitters (e.g., blue+yellow, red+green+blue, or other suitable colorcombinations) may be perceived by a viewer as white light. Variousmethods for generating white light from solid state emitters andphosphors are further disclosed in U.S. Pat. No. 7,213,940, which ishereby incorporated by reference as if set forth fully herein.

Given the enormous installed base of incandescent lamps and lightfixtures having threaded Edison-type sockets, a substantial financialincentive exists for manufacturers to produce solid state lamps capableof being retrofitted into existing Edison-type threaded fixtures.Edison-type threaded sockets are conventionally used to powerincandescent light bulbs from an AC power source, with such a socketarranged to mate with a male base including a screw thread contact andan electrical foot contact.

Solid state emitters require constant current to maintain proper lightemission. If current to a solid state emitter varies, the luminousintensity and chromaticity may vary (e.g., white LEDs may shift towardblue in color) and excessive heating may result, potentially leading toshortened life or damage. White LEDs are conventionally powered indifferent ways, including: (a) a current source and ballast resistors;(b) multiple current sources; and (c) a current source (e.g.,inductor-based boost converter) with multiple LEDs in series connection.Each of the foregoing power circuit types are advantageously implementedwith components mounted to a printed circuit board (PCB), optionallyincluding at least one integrated circuit and/or processor. Dimming isalso a concern for white LED emitters, since standard TRIAC-baseddimming schemes applicable to incandescent lamps are not directlyapplicable to LEDs. LED dimming is typically done through pulse widthmodulation (PWM), rather than TRIAC-based dimming (which delays turningon energy to a bulb following every zero crossing of an AC powersource). To enable white light LEDs to interface with TRIAC-baseddimmers, a driver circuit (such as the National Semiconductor LM3445)can be used to monitor the waveform from a standard TRIAC dimmer andadjust same to supply the correct PWM duty cycle and current. Suchdriver circuitry is also desirably implemented with components mountedto a PCB. Further control circuitry may be associated with a PCB toadjust color and/or chromaticity of solid state emitters. A PCB andassociated circuitry may be desirably contained within a housing (orenvelope) of a solid state lighting device to protect the circuitry fromimpact and/or exposure to ambient conditions.

With reference to FIGS. 1A-1C, a conventional method for assembling athreaded Edison base solid state lighting device having a PCB involvesmultiple steps, including establishment of electrical connections to thePCB. FIG. 1A depicts a PCB 10, a housing 20, and an Edison cap 30. ThePCB 10 has electrical components 15 mounted thereon and interface wires11, 12, to form a PCB assembly 5. The housing 20 includes a first openend 21, a second open end 22, and progressively larger stepped first,second, and third body portions 25A-25C with intermediate transitions orshoulders 26A-26B therebetween. Screw threads 24 are provided on alateral surface of the first body portion 26A. The housing 20 defines acavity or hollow interior 29. An attachment lug 28 including an aperture28 protrudes outward from the third body portion 25C. The generallycylindrical Edison cap 30 includes a threaded sidewall contact 34, aninsulating transition 33, and a protruding foot contact 32 defining anaperture 31 therein. A first step in establishing electrical connectionto the PCB 10 and components 15 thereon includes soldering the twointerface wires 11, 12 to the PCB 10 (e.g., for line and neutralconnections). Next, the PCB assembly 5 is inserted into the cavity 29 ofthe housing 20 and the wires 11, 12, are routed out of the open top end21. As shown in FIG. 1B, one wire 11 is routed against the first bodyportion 25A to mate with the threads 24, and the other wire 12 is routedthrough the interior of the Edison cap 30 to project through theaperture 31 defined in the foot contact 32. The Edison cap 30 is thenscrewed into position (as shown in FIG. 1C) to engage the threads 24 andenclose the first end 21 of the housing 20, with the wires 11, 12,protruding from the bottom of the sidewall 34 and from the aperture 31,respectively. Thereafter the two wires 11, 12, are soldered in theirrespective positions and trimmed flush to the solder joints (not shown).The foregoing steps in combination are not susceptible to inexpensiveautomation, and therefore require substantial labor for completionthereof.

A solid state lighting device 60 comprising the PCB 10 with components15, the housing 20, and the Edison cap 30 is illustrated in FIGS. 2A-2B.In addition to the components described in connection with FIGS. 1A-1C,the lighting device 60 includes fins 40 associated with the body 20 todissipate heat generated by the lighting device 60, a reflector 40disposed below the PCB 10, at least one solid state light emittingelement 50 arranged to emit light toward the reflector 40, at least onesupport 42 for the at least one light emitting element 50, a lens 48,and a peripheral ring or bezel 43 disposed along an emitting end 44 ofthe device 60.

Other electrical devices having PCBs are fabricated by soldering wiresbetween PCB and externally accessible electrical connectors.Establishing such soldered connections is labor-intensive and providespotential for fabrication errors.

It is known to conduct DC supply power to low-current devices throughuniversal serial bus (USB) connectors that include metalized contacts onan insulating substrate. USB connectors are well-suited for chargingand/or powering low-current devices, but are generally not used toconduct AC power, and further may not be well-suited for light fixturesor applications requiring electrical currents exceeding one or moreamperes.

It would be desirable to reduce the labor associated with conventionalmethods for establishing electrical connections to a PCB during assemblyof electrical devices, including threaded Edison base solid statelighting devices. It would also be desirable to improve the reliabilityof such electrical connections, and improve manufacturing yield.

SUMMARY

The present disclosure relates to interfaces and fabrication methods forelectrical (e.g., lighting) devices, involving use of first and secondelectrically conductive edge contacts arranged on or protruding from anedge of a substrate (e.g., printed circuit board), with such edgecontacts either serving externally accessible electrical conductivecontacts or being in electrical communication with externally accessibleelectrical contact elements without use of intervening wires or solderedconnections.

In one aspect, the disclosure relates to a lighting device comprising: ahousing having associated therewith at least one externally accessibleelectrically conductive contact; at least one light emitting elementassociated with the housing; and a substrate arranged for insertion intoat least a portion of the housing, the substrate including at least oneelectrically conductive edge contact arranged on or protruding from anedge of the substrate, wherein the at least one externally accessibleelectrically conductive contact either (a) comprises the at least oneelectrically conductive edge contact, or (b) is in electricalcommunication with the at least one electrically conductive edge contactwithout use of any intervening wire or soldered connection; and thelighting device comprises at least one of the following features (i) and(ii): (i) the at least one externally accessible electrically conductivecontact is arranged to contact an AC power source and conduct AC power;and (ii) the housing comprises a plurality of openings, the at least oneexternally accessible electrically conductive contact comprises aplurality of externally accessible electrically conductive contacts, andeach opening of the plurality of openings is arranged to receive adifferent externally accessible electrically conductive contact of theplurality of externally accessible electrically conductive contacts.

In another aspect, the disclosure relates to a lighting devicecomprising: a housing including a male base, at least one lightingemitting element associated with the housing; and a printed circuitboard (PCB) configured for electrical connection to the at least onelight emitting element, the PCB including an end within the male base,and at least one electrically conductive edge contact arranged on orprotruding from an edge of the PCB, wherein the at least oneelectrically conductive edge contact either (a) protrudes through anopening defined in the male base to form at least one externallyaccessible electrically conductive contact, or (b) is in electricalcommunication with at least one externally accessible electricallyconductive contact without use of any intervening wire or solderedconnection; and the lighting device comprises at least one of thefollowing features: (i) the at least one externally accessibleelectrically conductive contact is arranged to contact an AC powersource and conduct AC power; and (ii) the housing comprises a pluralityof openings, the at least one externally accessible electricallyconductive contact comprises a plurality of externally accessibleelectrically conductive contacts, and each opening of the plurality ofopenings is arranged to receive a different externally accessibleelectrically conductive contact of the plurality of externallyaccessible electrically conductive contacts.

In another aspect, the disclosure relates to a printed circuit board(PCB) adapted for use with a lighting device including a housingdefining a screw-shaped male base with a protruding tip, the baseincluding or having associated therewith an externally accessibleelectrical lateral contact, and the base including or having associatedtherewith an externally accessible electrical foot contact at theprotruding tip, wherein the PCB comprises (i) at least a portionarranged for insertion into the male base; (ii) a first electricallyconductive edge contact arranged on or protruding from an edge of thePCB and adapted to either (a) protrude through a lateral opening in themale base to form the electrical lateral contact, or (b) directly engagethe electrical lateral contact, and (iii) a second electricallyconductive edge contact arranged on or protruding from an edge of thePCB and adapted to either (a) protrude through a tip opening in the malebase to form the electrical foot contact, or (b) directly engage theelectrical foot contact.

In another aspect, the disclosure relates to lighting device comprisingan electrically insulating housing including a screw-shaped male basewith a protruding tip, an externally accessible electrical lateralcontact, and an externally accessible electrical foot contact, thelighting device being characterized by at least one of the followingfeatures (a) and (b): (a) the lateral contact is adapted tocompressively engage a first electrically conductive edge contactarranged on or protruding from an edge of a printed circuit board (PCB)adapted for insertion into the housing; and (b) the foot contact isadapted to compressively engage a second electrically conductive edgecontact arranged on or protruding from an edge of a printed circuitboard (PCB) adapted for insertion into the housing.

In a further aspect, the disclosure relates to a method for fabricatinga lighting device, the method comprising inserting into a housing acircuit board having a first electrically conductive edge contactarranged on or protruding from an edge of the circuit board and having asecond electrically conductive edge contact arranged on or protrudingfrom an edge of the circuit board, wherein said insertion causes thefirst electrically conductive edge contact to either (a) protrudethrough at least one opening in the housing to form a first externallyaccessible electrical contact, or (b) directly engage a first externallyaccessible electrical contact element associated with the housing, andwherein said insertion causes the second electrically conductive edgecontact to either (a) protrude through at least one opening in thehousing to form a second electrically accessible electrical contact, or(b) directly engage a second externally accessible electrical contactelement associated with the housing.

In another aspect, any one or more aspects or features may be combinedfor additional advantage.

Other aspects, features and embodiments of the disclosure will be morefully apparent from the ensuing disclosure and appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a photograph depicting as unassembled a perspective view of ahousing of an Edison base lighting device, a perspective view of aprinted circuit board (PCB) with control elements sized for placementwithin the housing portion, and a perspective view of a threaded Edisoncap arranged to mate with an externally threaded portion of the housing.

FIG. 1B is a perspective view photograph depicting the housing, PCB, andEdison cap of FIG. 1A in a partially assembled state, with the PCBinserted into the housing, but prior to engagement of the threadedEdison cap to the housing.

FIG. 10 is a perspective view photograph depicting the housing, PCB, andEdison cap of FIGS. 1A-1B in a further assembled state, with the PCBinserted into the housing, and with the threaded Edison cap engaged tothe housing.

FIG. 2A is a perspective cutaway view of an Edison-type threaded basesolid state lighting device including the housing portion, PCB withcontrol elements, and Edison cap of FIGS. 1A-1C.

FIG. 2B is a side elevation view of the solid state lighting device ofFIG. 2A.

FIG. 3A is a simplified perspective cutaway view of at least a portionof a lighting device with a threaded male base according to oneembodiment of the present disclosure, the lighting device including aprinted circuit board with a first electrically conductive edge contactprotruding through a lateral opening in the male base to form a lateralelectrical contact, and with a second electrical edge contact thatextends through a tip of the threaded male base to form an electricalfoot contact.

FIG. 3B is a perspective view of the lighting device portion of FIG. 3A.

FIG. 4A is a perspective cross-sectional view of a portion of a housingof a lighting device with a threaded male base according to anotherembodiment of the present disclosure, with a slot-defining electricallyconductive pin insert molded into a protruding tip of the threaded malebase to form an electrical foot contact.

FIG. 4B is a perspective view of the slot-defining electricallyconductive pin illustrated in FIG. 4A.

FIG. 4C is a simplified perspective cutaway view of at least a portionof a lighting device including the housing and slot-definingelectrically conductive pin of FIG. 4A, and including a printed circuitboard with a first electrically conductive edge contact protrudingthrough a lateral opening in the male base to form a lateral electricalcontact, and with a second electrical edge contact inserted into theslot to directly engage the electrically conductive pin that forms theelectrical foot contact.

FIG. 4D is a perspective view of the lighting device portion of FIG. 4C.

FIG. 5A is a perspective assembly view of a portion of an electricaldevice, including a housing portion and a circuit board portion with twoedge contacts arranged for insertion into the housing portion, the twoedge contacts extending above the circuit board and affixed to one faceof the circuit board.

FIG. 5B is a perspective view of a first alternative circuit boardportion with two edge contacts extending above the circuit board andaffixed to an upper edge of the circuit board.

FIG. 5C is a perspective view of a second alternative circuit boardportion with first and second edge contacts extending above the circuitboard and affixed to opposing faces of the circuit board.

FIG. 6 is a perspective assembly view of a portion of another electricaldevice, including a housing portion and a circuit board portion with twoedge contacts arranged for insertion into the housing portion, the twoedge contacts extending above the circuit board and affixed to opposingfaces and an upper edge of the circuit board.

DETAILED DESCRIPTION

The present disclosure relates to improved interfaces and fabricationmethods for electrical (e.g., lighting) devices incorporating printedcircuit boards (PCBs) or other substrates, by eliminating the need forsoldered connecting wires between PCBs/substrates and externallyaccessible electrical contacts. Wired connections may be eliminated byuse of PCB edge contacts. Certain embodiments relate to includeEdison-type screw-shaped threaded male base lighting devices

The term “edge contact” as used herein refers to an electricallyconductive contact disposed along an edge of a substrate (e.g., a PCB).An edge contact may be arranged on or protruding from an edge of asubstrate. In certain embodiments, an edge contact may includeelectrically conductive material (e.g., copper, gold, or anothersuitably conductive metal, or a conductive polymer) metalized orotherwise disposed at least on an edge of the PCB, preferably extendingto at least one face of the PCB, and more preferably extending to bothopposing faces of the PCB. Electrically conductive material may bedeposited according to conventional metallization processes. In certainembodiments, an edge contact may include an electrically conductivematerial (e.g., a plate, a clip, a plug, or the like) engaged on oragainst a portion of a PCB to extend from an edge of the PCB.

At least one opening may be defined in a housing of an electrical (e.g.,lighting) device to receive at least one edge contact of a PCB andenable the at least one edge contact to extend through the housing. Inone embodiment, an edge contact of a PCB protrudes through a lateralopening defined in a male base, with the edge contact including a flutededge defining protrusions and grooves arranged to follow a lateralprofile of threads of a screw-shaped male base. Such conformation allowsa lateral edge contact to protrude through a lateral opening of the malebase without interfering with the ability to screw the male base into acorresponding threaded socket of a lamp or other light fixture. Inanother embodiment, an edge contact of a PCB comprises a substantiallyflat or smooth edge lacking protrusions or grooves, with the flat orsmooth edge arranged to protrude through a lateral opening defined inthe male base to a lateral extent that is less than projecting portionsof the threads of the base, but that is greater than or equal torecessed portions of the threads of the base. In such an embodiment,upon threaded insertion of the lighting device into a female threadedsocket, the flat or smooth edge of the PCB would still be arranged tocontact the threaded side wall of the female socket, in order to makeelectrical contact between the threaded socket side wall and the flat orsmooth edge of the (lateral) edge contact.

In one embodiment, an opening is defined in a protruding tip of ascrew-shaped male base, and an edge contact of a PCB protrudes throughsuch opening to form an electrical foot contact of a lighting device.

In another embodiment, at least one edge contact of a PCB does notextend through an opening defined in a housing of a lighting device, butrather is directly engaged with an externally accessible electricallyconductive contact element forming an electrical foot contact or alateral contact of a lighting device. An externally accessible contactelement is preferably located along an external portion of an electricaldevice, and is preferably arranged for connection to a power source orcircuit element. An externally accessible electrically conductivecontact element may be integrally formed with at least a portion of thehousing, which may be electrically insulating in character, or theconductive contact element may be prefabricated and affixed to orinserted into an electrical insulating portion of the housing by aprocess including at least one of insert molding, heat staking (e.g.,including heating of the housing and pressing or insertion of theconductive contact element), ultrasonic insertion, spin welding, pressfitting (with or without heating), and application of pressureoptionally aided by heating of the housing and/or cooling of theconductive contact element. “Direct engagement” refers generally toconnection without an intervening wire, and preferably to the absence ofan intervening soldered connection. Direct engagement preferablyincludes mechanical contact, which may be maintained with a biasingforce and/or mechanical compression (e.g., compressive engagement). Oneor more conductive elements may be retained by the housing to form alateral contact and/or a foot contact for a lighting device, with one ormore edge contacts of a PCB arranged to directly engage (e.g.,compressively engage) the one or more externally accessible electricallyconductive contact elements. In one embodiment, an externally-accessibleconductive element forming an electrical foot contact or a lateralcontact of a lighting device defines a slot bounded by electricallyconductive material within the housing of a lighting device, and a PCBedge contact is inserted into the slot to provide direct engagement.Such a slot may be tapered to promote compressive engagement between theconductive element and the edge contact. Biasing elements, springs,gaskets, washers, and the like may alternatively or additionally be usedwithin a housing to promote maintenance of direct contact between a PCBedge contact and an interior portion of a conductive element disposedwithin a housing of a lighting device—with the conductive element havinganother portion that is accessible along the exterior of the lightingdevice. In one embodiment, a first conductive element is retained byportion of a housing to form an externally accessible lateral contactfor a lighting device, and a second conductive element is retained by aportion of the housing to form an externally accessible foot contact forthe lighting device, with a first edge contact of a PCB arranged todirectly engage the first conductive element within the housing, andwith a second edge contact of the PCB arranged to directly engage thesecond conductive element within the housing.

In one embodiment, a PCB adapted for use with a screw-shaped male baselighting device includes a first electrically conductive edge contactthat either (a) protrude through a lateral opening in the male base toform an electrical lateral contact, or (b) directly engage an electricallateral contact; and includes a second electrically conductive edgecontact that either (a) protrudes through a tip opening in the male baseto form an electrical foot contact of the lighting device, or (b)directly engages an electrical foot contact of the lighting device,wherein the electrical lateral contact is arranged along a threadedlateral surface of the screw-shaped male base, and the electrical footcontact is arranged at a protruding tip of the screw-shaped male base.

A PCB or other substrate as referenced herein preferably has mountedthereon or associated therewith at least one component arranged tocontrol or affect operation of a light emitting element or otherelectronic element. In various embodiments, a PCB includes a ballastand/or a driver for at least one light emitting element. A PCB mayinclude a dimming circuit. A light emitting element advantageouslyincludes at least one solid state light emitting element. At least onesolid state light emitting element may include at least one emitter orcombination of emitters arranged to emit light perceived as white. Incertain embodiments, at least one light emitting element comprises afluorescent lamp, a high intensity discharge lamp, an incandescent lamp,and/or a halogen lamp. A plurality of emitters may be provided in asingle lamp, including emitters arranged to emit different colors. Inone embodiment, each emitter of a plurality of emitters is separatelycontrollable. A PCB may include components and/or circuits to controlindividual emitters of a plurality of emitters in a lighting device. APCB may include one or more integrated circuits and/or microprocessors,and one or more memory elements. A PCB may receive one or more inputsignals (e.g., user inputs, sensory inputs, network inputs, externalcontroller inputs, and the like) and may generate one or more outputsignals. Operation of one or more emitters of a lighting device may beresponsive to user inputs, sensory inputs, network inputs, and/orexternal controller inputs. Output signals may be used to operate one ormore emitters of a lighting device, to generate user-perceptible alarms(e.g., audio and/or visual signals), to generate output data, and tocoordinate operation with one or more light sources external to thelighting device.

In one embodiment, at least one sensor is electrically coupled to a PCBas disclosed herein, and extends into and/or through a housing of anelectrical device.

At least a portion of a lighting device 160 including a PCB with edgecontacts according to a first embodiment is depicted in FIGS. 3A-3B. Thelighting device 160 includes a housing 120 defining a cavity or hollowinterior 129 arranged to receive a PCB 10. The housing 120 includesprogressively larger stepped first, second, and third body portions125A-125C with intermediate transitions or shoulders 126A-126Btherebetween, and having associated fins 140 for heat dissipation. Thefirst body portion 125A constitutes a threaded male base, which includesa threaded sidewall portion 124 and also defines a lateral opening(e.g., rectangular slot or other shape) 127 arranged to receive an edgecontact 112 of a PCB 110 to form a lateral contact of the lightingdevice 160. This edge contact 112 is preferably fluted in shape, anddefines protrusions and grooves arranged to follow the lateral profileof threads 124 of the screw-shaped first body portion or base 125. Aprotruding portion 133 extends axially from the first body portion orbase 125A. A tip aperture or tip opening 131 is defined in theprotruding portion 133 and is arranged to receive another edge contact111 of the PCB 110 to form an electrical foot contact of the lightingdevice 160. This edge contact 111 may be rounded in character to followor conform to a rounded tip of the protruding portion 133. The tipopening 131 may be in any suitable shape, such as a rectangular slot, asubstantially circular opening, or any other desired shape.

A method for fabricating the lighting device 160 includes inserting thePCB 110 (preferably including electrical components mounted thereon)into the housing 120, sufficient to cause one electrically conductiveedge contact 112 to either (a) protrude through a lateral opening 127 inthe first body portion or base 125A to form an electrical contact or (b)directly engage an electrical lateral contact (not shown), andsufficient to cause another electrically conductive edge contact toeither (a) protrude through the tip opening 131 in the protrudingportion 133 of the male base to form an electrical foot contact of thelighting device 160, or to directly engage an electrical foot contact(not shown) of the male base. More generically, insertion of a PCB intoa housing may cause a first electrically conductive edge contact toeither (a) protrude through at least one opening in the housing to forma first externally accessible electrical contact, or (b) directly engagea first externally accessible electrical contact element associated withthe housing, and may further cause a second electrically conductive edgecontact to either (a) protrude through at least one opening in thehousing to form a second externally accessible electrical contact, or(b) directly engage a second externally accessible electrical contactelement associated with the housing. The PCB 110 is preferablymechanically mounted or otherwise retained within the housing 120. Amethod for fabricating the lighting device may further includeestablishing electrical communication between the circuit board and atleast one emitter (e.g., at least one solid state emitter) associatedwith the lighting device. The PCB 110 preferably includes at least oneelectrical contact (preferably multiple contacts) arranged to supplypower to at least one emitter. The PCB may have associated therewith oneor more wires and/or other suitable electrically conductive elements, aswell as components arranged to control and/or affect operation of atleast one electrically operative element (e.g., light emitters). In oneembodiment, a PCB includes at least one of an integrated circuit, amicroprocessor, and a memory element. A PCB may further include at leastone associated input element that is externally accessible through ahousing of an electrical device. Such input element may include, forexample, a sensor port, a communication port, a data interface port,and/or a programming port.

At least a portion of a lighting device 260 including a PCB 210 withedge contacts according to a first embodiment is depicted in FIGS. 4A,4C, and 4D. Such embodiment utilizes an electrically conductive insert(e.g., pin) 270 arranged to directly contact an edge contact 211 of aPCB 210 disposed within the interior 229 of the housing 220 of thelighting device 260. The conductive insert or pin 270 comprises anexternally accessible tip 271 (that is preferably rounded orhemispherical in shape), a cylindrical body 273, a retaining structure(e.g., flared lip) 274, and a first leg 275A and a second leg 275Bdefining a slot 276 therebetween. The electrically conductive insert 270is preferably integrally formed (e.g., insert molded) with at least theprotruding portion 233 of the housing 200. At least the protrudingportion 233 of the housing 220 may be electrically insulating incharacter. The retaining structure 274 is arranged to provide facilitatemechanical retention of the electrically conductive insert 270 withinthe protruding portion 233 of the housing 220, so as to preventextraction or removal of the insert 270 from the housing 220. Althoughthe retaining structure 274 is illustrated in FIGS. 4A-4C as being inthe form of a protruding lip, it is to be appreciated that one or moreprotrusions and/or recesses may be substituted or additionally providedto provide similar mechanical retention utility.

The lighting device 260 includes a housing 220 defining a cavity orhollow interior 229 arranged to receive a PCB 210. The housing 220includes progressively larger stepped first, second, and third bodyportions 225A-225C with intermediate transitions or shoulders 226A-226Btherebetween, and having associated fins 240 for heat dissipation. Thefirst body portion 225A constitutes a threaded male base, which includesa threaded sidewall portion 224 and also defines a lateral opening orslot 227 arranged to receive an edge contact 212 of the PCB 210 to forma lateral contact of the lighting device 260. This edge contact 212 ispreferably fluted in shape, and defines protrusions and grooves arrangedto follow the lateral profile of threads 224 of the screw-shaped firstbody portion or base 225, thus avoiding interference with an ability toscrew the male base into a corresponding threaded socket of a lamp orother light fixture (not shown). A protruding portion 233 of the housing220 extends axially from the first body portion or base 225A.

After the electrically conductive insert 270 is disposed (e.g.,retained) in the protruding portion 233 of the housing 220 for form anelectrical foot contact, a PCB 210 (preferably including electricalcomponents mounted thereon) is inserted into the housing 220, sufficientto cause a first electrically conductive edge contact 212 to protrudethrough the lateral opening 227 in the first body portion or base 225A,and sufficient to cause a second electrically conductive edge contact211 to be inserted between conductive legs 275A, 275B into the slot 276and directly engage the electrically conductive insert 270 that forms anelectrical foot contact of the lighting device 160. The PCB 210 ispreferably mechanically mounted or otherwise retained within the housing220.

The use of PCBs with edge contacts as described herein to serve as ordirectly engage outwardly accessible contacts of a lighting devicegreatly simplifies manufacturing, because steps associated withsoldering wires to a PCB, routing wires through the housing, solderingwire ends to an Edison cap, and trimming wires after soldering, areavoided. Manufacturing costs are reduced, and electrical connections ofhigh reliability are attained.

Although screw-shaped male base lighting devices with PCBs have beendescribed herein with emphasis on use with solid state emitters (e.g.,LEDs), it is to be appreciated that devices and fabrication methodsdescribed herein are applicable to lighting devices embodying otherconnection types (including but not limited to multi-pin lampconnectors) and other types of emitters, including, for example,fluorescent emitters, high intensity discharge emitters, incandescentemitters, and/or halogen emitters.

In preferred embodiments, at least one electrically accessibleconductive contact (e.g., an edge contact, or a contact in electricalcommunication with at least one externally accessible electricallyconductive contact without use of any intervening wire or solderedconnection) is arranged to contact an AC power source and conduct ACpower. In various embodiments, the AC power source may have a linevoltage of at least about 100V, at least about 110V, at least about120V, or at least about 220V. A printed circuit board with which one ormore edge connectors is associated may include at least one AC/DCconversion element (e.g., a rectifier). A PCB may further include atleast one of a driver and a ballast for at least one light emittingelement.

In certain embodiments, the housing of an electrical device (e.g., alighting device) includes multiple openings each arranged to receive adifferent externally accessible electrically conductive contact. In oneembodiment, each opening is arranged to receive a different electricallyconductive edge contact. Different edge contacts received by differentopenings in a housing may be associated with different regions of asingle PCB, or with different PCBs. Externally accessible electricallyconductive contacts (e.g., edge contacts) may extend into or throughopenings defined in the housing. Presence of multiple contacts receivedby different openings in a housing of an electrical device may bebeneficial to provide structural support to the contacts or underlyingsubstrates, and to guard against inadvertent short-circuiting byconductive materials that may be placed in proximity to the contacts.

The foregoing structures and fabrication methods are also applicable toelectrical devices generically, whether or not including lightingdevices, and whether or not including threaded base Edison connectors.

FIG. 5A is a perspective assembly view of a portion of an electricaldevice 300, including a housing portion 320 and a circuit board orsubstrate portion 310 with two edge contacts 311, 312 arranged forinsertion into the housing portion 320. The housing portion 320 includesopenings 327, 328 arranged to permit insertion of the edge contacts 311,312 therethrough. The circuit board 310 includes a first face 318,second face 319, and a border or edge portion 319. The two edge contacts311, 312 extend above an upper end of the circuit board portion 310 andare affixed to the first face 318 of the circuit board 310 alongconductive pads 313, 314. It is to be appreciated that a circuit board310 may include numerous traces and associated electrical components(including traces in electrical communication with at least one edgecontact and associated contact pads), but such traces and componentshave been omitted to promote clarity in explaining this embodiment ofthe present disclosure. Any of various types of mechanical supports (notshown) may be affixed to the circuit board 310 to support the edgecontacts 311, 312. Although the edge contacts 311, 312 are shown asbeing substantially cylindrical in shape, edge contacts of any suitableshape, size, and conformation may be substituted. Upon insertion of thecircuit board portion 310 into the housing 320, the edge contacts 311,312 are preferably arranged to extend through the openings 327, 328 toprotrude outward from the housing 310. In one embodiment, followinginsertion of a circuit board into a housing, edge contacts associatedwith the circuit board may be recessed within the housing (e.g., asfemale contacts arranged to receive an external male connector ofcompatible type (not shown)), but such recessed contacts still remainexternally accessible. The circuit board 310 preferably includes anelectrically insulating core material (e.g., FR-4) onto which one ormore conductive portions such as pads 313, 314 (formable from copper,another metal, or a conductive polymer) may be deposited. At least aportion of the housing 310 may be electrically insulating to preventshort-circuiting between the edge connectors 311, 312.

FIGS. 5B-5C depict alternative circuit board portions arranged for usewith a housing such as the housing 320 illustrated in FIG. 5A. In FIG.5B, two edge contacts 331, 332 extend above an upper end of a circuitboard 330 including a first face 338, a second face 339, and a border oredge portion 335. The two edge contacts 331, 332 are affixed to an upperedge 335 of the circuit board 330 along conductive pads 333, 334, whichpreferably extend along at least one face 338 and an edge portion 335 ofthe circuit board 330. In FIG. 5C, two edge contacts 351, 352 extendabove an upper end of a circuit board 350 including a first face 358, asecond face 359, and a border or edge portion 355. The two edge contacts351, 352 are affixed to the first face 358 and second face 359,respectively, of the circuit board 350. The first face 358 includes aconductive pad 353 along the first edge contact 351; a similarconductive pad (not shown) is preferably provided along the second face359 of the circuit board 350. Conductive traces and electrical and/orelectronic components may be provided on one or both faces of a circuitboard.

In one embodiment, edge contacts may be affixed to both faces and anupper edge of a circuit board. FIG. 6 is a perspective assembly view ofa portion of an electrical device 400, including a housing portion 420and a circuit board portion 410 with two edge contacts 411, 412. Atleast a portion of the circuit board 410 is arranged for insertion intoan interior of the housing portion 420. The two edge contacts 411, 412protrude upward from the circuit board 410 and are affixed to both faces418, 419 and an upper edge 415 of the circuit board 410 with associatedelectrically conductive contact pads 413, 414. In one embodiment, thecontact pads 413, 414 an edge contacts 411, 412 may be prefabricated(integrally formed) and affixed to the circuit board 410 using anyappropriate means, including crimping, thermal bonding, soldering, andthe like. In one embodiment, the edge contacts 411, 412 may be sized andshaped for insertion into a conventional AC power outlet. One or moreadditional edge contacts (not shown) may be provided as a groundcontacts and/or additional power, control, sensory, and/or communicationcontacts to communicate signals to or from the electrical device 400 viathe circuit board 410.

An electrical device may include at least one electrically operativeelement. a housing having associated therewith at least one externallyaccessible electrically conductive contact; and a substrate (e.g., aprinted circuit board) arranged for insertion into at least a portion ofthe housing. The substrate may include at least one electricallyconductive edge contact arranged on or protruding from an edge of thesubstrate. At least one externally accessible electrically conductivecontact either (a) includes the at least one electrically conductiveedge contact, or (b) is in electrical communication with the at leastone electrically conductive edge contact without use of any interveningwire or soldered connection. At least one externally accessibleelectrically conductive contact may be arranged to contact an AC powersource and conduct AC power.

In one embodiment, at least one externally accessible electricallyconductive contact is prefabricated and is retained by a housing of anelectrical device, and at least one electrically conductive edge contactis arranged to engage a portion of the at least one externallyaccessible electrically conductive contact within the housing.

In one embodiment, an electrical device comprises a housing including amale base; and a printed circuit board (PCB) configured for electricalconnection to an electrically operative element, the PCB including anend within the male base, and at least one electrically conductive edgecontact arranged on or protruding from an edge of the PCB; wherein theat least one electrically conductive edge contact either (a) protrudesthrough an opening defined in the male base to form at least oneexternally accessible electrically conductive contact, or (b) is inelectrical communication with at least one externally accessibleelectrically conductive contact without use of any intervening wire orsoldered connection (i.e., by direct engagement). Edge contacts may formlateral and/or foot contacts.

An electrical device as disclosed herein may include any desirabletype(s) of electrically operable elements. In various embodiments,electrical devices according to the present disclosure may include audioand/or video devices, personal computing devices, telecommunicationdevices, lighting devices, heating and/or cooling devices, tools, pumps,blowers, personal care devices, and the like. In one embodiment, anelectrical device is arranged for connection to an AC power source. Inone embodiment, an electrical device is arranged for connection to a DCpower source, such as a cigarette lighter adapter in a motor vehicle.

In one embodiment, electrically conductive edge contacts are arranged tobe retractably deployed relative to the housing of an electrical device.Such retractable deployment may protect the electrically conductive edgecontacts for transport or periods of non-use, may minimize physicalinterference with adjacent items, and may provide improved aesthetics. Acircuit board to which the electrically conductive edge contacts aremounted may translate or rotate within a housing of an electrical devicebetween multiple positions, preferably via at least one or moreselectively operable manual or automated deployment mechanisms (e.g., asolenoid, a servomotor, a four-bar mechanism, a thumb slider, etc.)known in the art. Travel stops and/or biasing elements (e.g., springs,detents, compression elements, etc.) may be used to maintain theelectrically conductive edge contacts (e.g., and associated circuitboard) in any desired fully retracted or fully deployed position betweenretraction and deployment steps. Flexible connectors (e.g., ribboncables or the like) may be arranged between a moveable circuit board andany other electrically operable components associated with theelectrical device to maintain electrical connections following repeateddeployment and retraction steps.

While the invention has been has been described herein in reference tospecific aspects, features and illustrative embodiments of theinvention, it will be appreciated that the utility of the invention isnot thus limited, but rather extends to and encompasses numerous othervariations, modifications and alternative embodiments, as will suggestthemselves to those of ordinary skill in the field of the presentinvention, based on the disclosure herein. Correspondingly, theinvention as hereinafter claimed is intended to be broadly construed andinterpreted, as including all such variations, modifications andalternative embodiments, within its spirit and scope.

What is claimed is:
 1. A light bulb comprising: a cavity-defininghousing arranged between a contact-defining end and a light-transmittingend, and a male base proximate to the contact-defining end; a printedcircuit board (PCB) at least partially disposed within the housing,wherein the PCB includes a first electrically conductive edge contactarranged on or proximate to a transverse edge of the PCB, and the PCBincludes a second electrically conductive edge contact arranged on orproximate to a longitudinal edge of the PCB, with at least one boundaryof the second electrically conductive edge contact being arranged closerthan at least one boundary of the first electrically conductive edgecontact to the light-transmitting end; an externally accessibleelectrically conductive foot contact arranged at the contact-definingend; an externally accessible electrically conductive lateral contactarranged on or along a lateral surface of the male base; a firstcompressive electrical interface arranged between the foot contact andthe first electrically conductive edge contact, wherein the firstcompressive electrical interface is arranged to provide conductiveelectrical communication between the foot contact and the firstelectrically conductive edge contact; and a second compressiveelectrical interface arranged between the lateral contact and the secondelectrically conductive edge contact, wherein the second compressiveelectrical interface is arranged to provide conductive electricalcommunication between the lateral contact and the second electricallyconductive edge contact.
 2. The light bulb of claim 1, wherein the malebase is screw-shaped, and the foot contact is arranged at a tip of themale base.
 3. The light bulb of claim 1, wherein the first compressiveelectrical interface provides direct engagement between the foot contactand the first electrically conductive edge contact without use of anyintervening wire or soldered connection, and the second compressiveelectrical interface provides direct engagement between the lateralcontact and the second electrically conductive edge contact without useof any intervening wire or soldered connection.
 4. The light bulb ofclaim 1, wherein one or more of the first compressive electricalinterface or the second compressive electrical interface comprises atleast one spring element or biasing element.
 5. The light bulb of claim1, wherein the foot contact comprises an electrically conductive pinthat extends in a longitudinal direction between the contact-definingend and the PCB.
 6. The light bulb of claim 5, wherein the firstcompressive electrical interface comprises at least one spring elementor biasing element configured to promote engagement between theelectrically conductive pin and the first electrically conductive edgecontact.
 7. The light bulb of claim 5, wherein the electricallyconductive pin includes first and second conductive elements that areseparated by a gap and that extend in a direction toward thelight-transmitting end.
 8. The light bulb of claim 5, wherein theelectrically conductive pin is prefabricated and retained by anelectrically insulating portion of the housing.
 9. The light bulb ofclaim 5, wherein the electrically conductive pin is insert molded orheat staked into an electrically insulating portion of the housing. 10.The light bulb of claim 1, wherein the PCB comprises at least one of aballast circuit, a driver circuit, or a dimmer circuit arranged tosupply electrical signals to a plurality of solid state emittersarranged between the contact-defining end and the light-transmittingend.
 11. A light bulb comprising: a cavity-defining housing arrangedbetween a contact-defining end and a light-transmitting end, and a malebase proximate to the contact-defining end; a printed circuit board(PCB) at least partially disposed within the housing, wherein the PCBincludes a first electrically conductive edge contact arranged on orproximate to a bottom edge of the PCB, and the PCB includes a secondelectrically conductive edge contact arranged on or proximate to alateral edge of the PCB, with at least one boundary of the firstelectrically conductive edge contact being arranged closer than at leastone boundary of the second electrically conductive edge contact to thecontact-defining end, and with the at least one boundary of the secondelectrically conductive edge contact being arranged closer than the atleast one boundary of the first electrically conductive edge contact tothe light-transmitting end; an externally accessible electricallyconductive foot contact arranged at the contact-defining end; anexternally accessible electrically conductive lateral contact arrangedon or along a lateral surface of the male base; and a compressiveelectrical interface arranged between the foot contact and the firstelectrically conductive edge contact, wherein the compressive electricalinterface is arranged to provide conductive electrical communicationbetween the foot contact and the first electrically conductive edgecontact; wherein the second electrically conductive edge contact extendsthrough an aperture defined in the housing to define the lateralcontact, with the second electrically conductive edge contact beingexternally accessible along the lateral surface of the male base. 12.The light bulb of claim 11, wherein the male base is screw-shaped anddefines threads configured to be received by a threaded socket of alighting device, and the second electrically conductive edge contactcomprises a fluted edge defining a plurality of protrusions and aplurality of grooves arranged to follow a lateral profile of the threadsof the screw-shaped male base.
 13. A method for fabricating a lightbulb, the method comprising inserting, into a housing, a printed circuitboard (PCB) including a first electrically conductive edge contactarranged on or protruding from a transverse edge of the PCB andincluding a second electrically conductive edge contact arranged on orprotruding from a longitudinal edge of the PCB, with at least oneboundary of the second electrically conductive edge contact beingarranged closer than at least one boundary of the first electricallyconductive edge contact to a light-transmitting end of the light bulbthat opposes a contact-defining end of the light bulb; wherein saidinsertion causes the first electrically conductive edge contact toengage an externally accessible electrically conductive foot contactretained by an electrically insulating portion of the housing, with afirst compressive electrical interface arranged between the foot contactand the first electrically conductive edge contact, to provideconductive electrical communication between the foot contact and thefirst electrically conductive edge contact; and wherein said insertioncauses the second electrically conductive edge contact to engage anexternally accessible electrically conductive lateral contact associatedwith the housing, with a second compressive electrical interfacearranged between the lateral contact and the second electricallyconductive edge contact, to provide conductive electrical communicationbetween the lateral contact and the second electrically conductive edgecontact.
 14. The method of claim 13, wherein one or more of the firstcompressive electrical interface or the second compressive electricalinterface comprises at least one spring element or biasing element. 15.The method of claim 13, wherein the housing is arranged between thecontact-defining end and the light-transmitting end of the light bulb,and a screw-shaped male base is arranged proximate to thecontact-defining end.
 16. The method of claim 13, further comprisingmechanically mounting or retaining the PCB within the housing.
 17. Themethod of claim 13, wherein the foot contact comprises an electricallyconductive pin retained within an electrically insulating portion of thehousing.
 18. The method of claim 17, wherein the electrically conductivepin includes first and second electrically conductive elements that areseparated by a gap and that extend in a direction toward thelight-transmitting end, and wherein said insertion causes the firstelectrically conductive edge contact to extend into the gap and becompressively engaged between the first and second electricallyconductive elements.
 19. The method of claim 17, wherein theelectrically conductive pin is prefabricated, and the method furthercomprises affixing the electrically conductive pin to the housing, or toa base associated with the housing, by a process including at least oneof: insert molding, heat staking, ultrasonic insertion, spin welding, orpress fitting.
 20. The method of claim 13, further comprisingestablishing electrical communication between the PCB and at least onesolid state emitter of the light bulb.